Apparatus for making cast chain

ABSTRACT

A method and apparatus for casting a plurality of spaced apart chain links and connecting links therebetween in the same molding apparatus. The molds for casting the spaced apart links are formed in the cope and drag portions of the molding apparatus, and the adjacent sides of the molds are intersected by elongated vertical recesses which receive upstanding core assemblies containing arcuate passages to complete the molds for the spaced apart links. The upstanding core assemblies also contain molds for casting vertical connecting links between the horizontally spaced apart links. After casting two or more such plural link chains, they may be connected together to provide a chain of any desired length by casting connecting links between the end links of each chain using other core assemblies.

United States Patent Wheeler 1 Sept. 12, 1972 [54] APPARATUS FOR MAKINGCAST CHAIN 72 Inventor: J. Stanley Wheeler, Baltimore, Md.

[73] Assignee: Unitec Industries, Inc., 2, York, Pa.

[22] Filed: Nov. 27, 1970 [21] Appl. No.: 93,261

[52] US. Cl ..164/351, 59/35 [51] Int. Cl ..B22c 9/22 [58] Field ofSearch 164/l0, 11,108,129, 130, 164/350, 351; 18/DIG. 34, DIG. 62;59/72,

[56] References Cited UNITED STATES PATENTS 1,262,613 4/1918 Mumford..164/11 3,176,357 4/1965 Nelson ..18/DIG. 62 2,348,979 5/ 1944 Kloss..249/57 X 1,920,578 8/1933 Matzow ..249/57 X 1,365,672 1/ 1921 Fawcett..164/11 1,398,706 Ill 1921 Rust ..249/57 X 2,764,790 10/ 1956 Nelson..249/57 2,786,248 3/1957 Nelson ..249/57 Primary Examiner.l. SpencerOverholser Assistant Examiner-John S. Brown Attorney-()berlin, Maky,Donnelly & Renner ABSTRACT A method and apparatus for casting aplurality of spaced apart chain links and connecting links therebetweenin the same molding apparatus. The molds for casting the spaced apartlinks are formed in the cope and drag portions of the molding apparatus,and the adjacent sides of the molds are intersected by elongatedvertical recesses which receive upstanding core assemblies containingarcuate passages to complete the molds for the spaced apart links. Theupstanding core assemblies also contain molds for casting verticalconnecting links between the horizontally spaced apart links. Aftercasting two or more such plural link chains, they may be connectedtogether to provide a chain of any desired length by casting connectinglinks between the end links of each chain using other core assemblies.

5 Claims, 10 Drawing Figures PATENTED SE? 1 2 I972 SHEET 1 BF 3INVENTOR. J. STANLEY WHEEL 5/? i '54 2'4 25 2'6 is 24 25 A TTORNEYSPATENTED E 12 SHEET 2 BF 3 INVENTOR J. STANLEY WHEELER HY ///d flonnt1/9/6700! A T TORNEYS PATiNTEDszr 12 m2 3.690.369

sum 3 or 3 INVENTOR. J. STANLEY WHEELER ATTORNEYS APPARATUS FOR MAKINGCAST CHAIN This invention relates generally as indicated to a method andapparatus for making cast chain by casting plural spaced apart links andconnecting links therebetween using the same molding apparatus to reducehandling of the chain links and setup time.

l-Ieretofore, it was the usual practice to make individual preformedchain links from wire or bar stock by rolling the wire or bar stock tothe desired configuration and welding the ends of the links together.These preformed links were then made into a chain by welding connectingrings or links between pairs of the preformed links.

It was also common practice to precast every other link and then castconnecting links between the precast links in a subsequent operationusing connecting link cores to completely core around the precast links.Regardless of which procedure was used, the amount of handling and setuptime that was required first to form the individual links and later onform connecting links therebetween resulted in relatively highmanufacturing costs for the chain.

With the foregoing in mind, it is a principal object of this inventionto provide a method and apparatus by which both the spaced apart linksand connecting links of a chain are cast in the same mold assembly at asubstantial reduction in handling and setup time.

Another object is to provide a method and apparatus for connecting theend links of two or more plural link chains together to provide a chainof any desired length.

These and other objects of the present invention may be achieved using amolding apparatus in which plural spaced apart molds are provided forcasting the spaced apart horizontal links, and elongated verticalrecesses are also provided in the molding apparatus intersecting theadjacent sides of the molds for the spaced apart links. The recesses arefilled by upstanding core assemblies which contain arcuate passagestherethrough to complete the molds for the spaced apart links and alsocontain molds for casting vertical connecting links between thehorizontal links.

After casting two or more of the plural link chains, they may beconnected together using other core assemblies to cast connecting linksbetween the end links of each chain.

To the accomplishment of the foregoing and related ends the invention,then, comprises the features hereinafter fully described andparticularly pointed out in the claims, the following description andthe annexed drawings setting forth in detail a certain illustrativeembodiment of the invention, this being indicative, however, of but oneof the various ways in which the principles of the invention may beemployed.

In the annexed drawings:

FIG. 1 is an isometric view showing one form of chain which may be madeutilizing the method and apparatus of the present invention;

FIG. 2 is a top plan view of the drag portion of the molding apparatusof the present invention in which a pattern has been formed providingone half of the molds for making the spaced apart links of the chain ofFIG. 1;

F IG. 3 is a bottom plan view of the cope portion of such moldingapparatus in which a matching pattern has been formed to complete themolds for making the spaced apart chain links of FIG. 1;

FIG. 4 is a partially exploded isometric view of the entire moldingapparatus with upstanding core assemblies for casting the verticalconnecting links shown in place in the drag portion of the moldingapparatus;

FIG. 5 is an enlarged isometric view of one of the core assemblies ofFIG. 4, the core halves being shown separated and facing upwardly toillustrate the internal configuration thereof;

FIG. 6 is an isometric view showing the pattern used to form the variousindentations in the drag half of the molding apparatus of FIG. 2;

FIG. 7 is an isometric view showing the pattern used to form theindentations in the cope half of the molding apparatus of FIG. 3;

FIG. 8 is an enlarged isometric view showing the core assembly used toconnect two chains together;

FIG. 9 is a vertical section through the core assembly and chain of FIG.8, taken on the plane of the line 9-9 thereof; and

FIG. 10 is a horizontal section through the core assembly and chain ofFIG. 8, taken on the plane of the line 10-10.

Referring now in detail to the drawing and first especially to FIG. 1,there is illustrated by way of example a chain 1 consisting of pluralspaced apart links 2 with connecting links 3 between adjacent pairs oflinks 2. Preferably, all of the links 2, 3 are cast in the same moldingapparatus to reduce handling and setup time, as will be more fullyexplained hereafter.

The chain links 2, 3 may be of any desired configuration depending uponthe type of chain being cast and particular use for which the chain ismade. Where the chain is to be used in rotary kilns, the links 2, 3 arepreferably circular as shown in FIGS. 1, 9 and 10 so that the wear pointengagement between links is con tinuously repositioned during rotationof the kiln, and the inner surface 4 of each link is also desirablyconvex but substantially flatter than a conventional link which iscylindrical in transverse section to distribute the wear-contactingengagement over wider areas than conventional links. The links 2, 3 alsodesirably have annular concave surfaces 5 which extend inwardly fromopposite sides of the links to provide a generally triangularcross-sectional configuration including a circular band portion 6 and abracing rib 7 which reinforces the band portion (see FIGS. 9 and 10).

Such a link configuration substantially reduces the overall weight ofthe links without sacrifice in the total exterior heat-transferringsurface of the links, and also aids in self-cleaning of the linksbecause of the manner in which the links tumble and rub against eachother during rotation of the kiln to remove accumulated materialtherefrom. Of course, a reduction in weight of the links also saves inmaterial and reduces the power requirements for rotating the kiln. Amore complete disclosure of the preferred link configuration for use inrotating kilns may be found in US. Pat. No. 3,281,134, granted toCharles F. Feiser, Jr. on Oct. 25, 1966, which is incorporated herein byreference.

To cast the plural spaced apart links 2 and connecting links 3therebetween in the same molding apparatus 10 requires the use ofspecial core assemblies 11 which are inserted in vertical alignedrecesses 12 and 13 in the cope and drag portions 14 and 15 of the moldassembly. As clearly shown in FIGS. 4 and 5, each such core assembly 11desirably consists of two identical halves 16 having annular grooves 17therein which cooperate to define a mold of the desired cross sectionalconfiguration for casting a connecting link 3 when the core halves 16are properly assembled and cemented together. The core halves 16 areeach slotted at 18 along the upper edge 19 to provide a gate 20communicating with the annular grooves 17 therein for introduction ofmetal into the core assembly. Notches 21 and 22 may be provided in theouter peripheries of the grooves 17 at the gate 20 and on the oppositeside thereof to provide symmetrical lugs 23 (see FIGS. 1 and 8-10) onopposite sides of the links. Providing a lug 23 in the region of thegate 20 facilitates removal of the excess metal from the links and thepurpose of the other lug 23 is to provide symmetry.

Also provided in the core halves l6 centrally of the annular grooves 17therein are a pair of arcuate passages 24 and 25 having a configurationcorresponding to the cross-sectional configuration of the cooperatinggrooves 26 formed in the cope and drag portions 14 and 15 of the moldingapparatus for casting the spaced apart links 2. As shown in FIGS. 2 and3, the grooves 26 which provide the molds for casting the spaced apartlinks 2 are substantially annular except where intersected by therecesses 12 and 13 for the upstanding core assemblies 11 previouslydescribed. Of course, with the core assemblies 11 inserted in therecesses 12 and 13 in the molding apparatus, the molds for the spacedapart links are completed by the arcuate passages 24 and 25 in the coreassemblies which line up with the grooves 26 in the cope and dragportions (see FIG; 4). The grooves 26 may also be provided with notches27 and 28 on opposite sides to form symmetrical lugs 30 on the spacedapart links 2, similar to the connecting links 3.

For introducing molten metal into the core assemblies 1 1 within thefinished molding apparatus 11), there is provided a pair of riserpassages 31 and 32 which extend through the cope portion 14 into theelongated recess 12 therein in vertical alignment with the core assemblygates 20. Also formed in the cope portion 14 is a pouring basin orreservoir 33 into which the molten metal for filling the molds for thespaced apart links is introduced. As best seen in FIGS. 2 through 4, thepouring basin 33 communicates with a runner 34 in the drag portion ofthe molding apparatus 10 for conducting the metal from the pouring basinto the various gates 35 in the cope portion 14 adjacent each mold fromwhich the metal enters the molds.

FIG. 6 illustrates the pattern 36 used to form the various grooves 26,runner 34, and elongated recess 13 in the green sand of the drag portion15 of the molding apparatus 10, whereas FIG. 7 illustrates the pattern37 for forming the corresponding grooves 26, elongated recess 12, gates35, and pouring basin 33 in the cope portion 14. The risers 31 and 32 inthe cope portion 14 are formed by attaching riser pins 38 to the uppersurface of the elongated recess forming portion 39 of the cope formingpattern 37.

The number of interconnected chain links which may be cast in a singlemolding apparatus 10 may of course be varied, but it has been found thata single molding apparatus may be effectively used to cast five links atone time; that is, three spaced apart links 2 with connecting links 3therebetween. After the casting operation, the chain 1 may be tumbledand/or sand blasted for improved appearance and flash removal, and thechain may also be heat treated if desired.

Chains of substantially greater length may be made by casting connectinglinks between the ends of the chains 1 formed as previously described.In FIGS. 8 through 10 there is shown a preferred form of core assembly40 which may be used to cast connecting links between the end links ofsuch plural link chains. Each core assembly 40 desirably consists of anupper half 41 and a lower half 42 having cooperating grooves 43 and 44in the mating faces thereof for receipt of a portion of the end links 2of two chains to be connected. Each mold half 41 and 42 is alsovertically divided to provide two upper parts 45 and 46 and two lowerparts 47 and 48 containing cooperating semi-circular grooves 49 and 50that define a mold cavity surrounding the grooves 43 and 44 for castingthe connecting link 51. A gate 52 extends through the top of the coreassembly 40 for introducing molten metal into the mold when the variousparts of the core assembly are properly assembled and cemented togetheras shown in FIG. 8. Opposite sides of the mold may be notched at'53 and54 as shown to provide symmetrical lugs 55 on the connecting links 51,similar to the links 2 and 3. The ends of the core assembly 40 are alsodesirably notched at 56 and 57 to provide clearance space for the nextlink of each chain being connected together. Any number of such plurallink chains 1 may be connected together at the same time usingadditional core assemblies 40 between the end links of each pair ofchains to be connected.

From the foregoing, it will now be apparent that the method andapparatus disclosed herein provide for the casting of a plural linkchain in a single molding apparatus at a substantial savings in handlingand setup time, and also provide for connecting any number of suchplural link chains together as desired.

The embodiments of the invention in which an exclusive property orprivilege is claimed are defined as follows:

1. Molding apparatus for casting a plurality of interconnected chainlinks comprising upper and lower mold portions having plural spacedapart grooves therein which provide plural spaced apart molds forcasting plural spaced apart links, means within said mold portionsproviding additional molds extending through adjacent pairs of saidspaced apart molds for casting connecting links between the spaced apartlinks, said means providing additional molds comprising core assembliesreceived in aligned recesses in said upper and lower mold portionsintersecting the adjacent sides of said spaced apart molds, said core assemblies having arcuate passages therein completing the portions of thespaced apart molds removed by the recesses, said core assemblies alsocontaining said additional molds for casting such connecting links, andpassage means in said molding apparatus communicating with said moldsthrough which molten metal is introduced to said molds.

2. The molding apparatus of claim 1 wherein said passage means forintroducing molten metal to said spaced apart molds comprises gates insaid upper mold portion adjacent each of said spaced apart molds, saidspaced apart molds having notches adjacent said gates and on theopposite side thereof which provide sym- 4. The molding apparatus ofclaim 1 wherein said passage means for introducing molten metal to saidmolds in said core assemblies comprises gates in said core assembliescommunicating with said molds therein, and passages in said upper moldportion communicating with said gates in said core assemblies.

5. The molding apparatus of claim 4 wherein said molds in said coreassemblies have notches adjacent said gates and on the opposite sidethereof which provide symmetrical lugs on such connecting links.

1. Molding apparatus for casting a plurality of interconnected chainlinks comprising upper and lower mold portions having plural spacedapart grooves therein which provide plural spaced apart molds forcasting plural spaced apart links, means within said mold portionsproviding additional molds extending through adjacent pairs of saidspaced apart molds for casting connecting links between the spaced apartlinks, said means providing additional molds comprising core assembliesreceived in aligned recesses in said upper and lower mold portionsintersecting the adjacent sides of said spaced apart molds, said coreassemblies having arcuate passages therein completing the portions ofthe spaced apart molds removed by the recesses, said core assembliesalso containing said additional molds for casting such connecting links,and passage means in said molding apparatus communicating with saidmolds through which molten metal is introduced to said molds.
 2. Themolding apparatus of claim 1 wherein said passage means for introducingmolten metal to said spaced apart molds comprises gates in said uppermold portion adjacent each of said spaced apart molds, said spaced apartmolds having notches adjacent said gates and on the opposite sidethereof which provide symmetrical lugs on such spaced apart links, arunner in said lower mold portion communicating with said gates, and areservoir in said upper mold portion communicating with said runner. 3.The molding apparatus of claim 1 wherein said core assemblies consist oftwo halves cemented together, each of said halves having annular groovestherein which cooperate to define said additional molds for casting suchconnecting links, said arcuate passages extending through said coreassembly halves centrally of said annular grooves therein.
 4. Themolding apparatus of claim 1 wherein said passage means for introducingmolten metal to said molds in said core assemblies comprises gates insaid core assemblies communicating with said molds therein, and passagesin said upper mold portion communicating with said gates in said coreassemblies.
 5. The molding apparatus of claim 4 wherein said molds insaid core assemblies have notches adjacent said gates and on theopposite side thereof which provide symmetrical lugs on such connectinglinks.